Six Sigma Case Study: Scrap Production

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A reduction in scrap production saved this company $96,000

Manifolds are produced with two manufacturing cells.  The overall average scrap rate of 9.06% for both cells was unacceptably high.  Through the use of Pareto charts the molding operation was identified as the primary contributor to scrap.

The ability of the inspectors to identify visual defects was analyzed through a GR&R.  It was found the operators needed training to consistently identify visual defects.  Statistical analysis verified the performance of press 19 was better than press 1569.  Operations of the cells were optimized using Design of Experiments.

With our six sigma consulting, the following improvements implemented were:

  • Operator training of visual criteria
  • Cleaning schedules were established for the mold plates and injection units for both cells
  • Injection profile modified as a result of Design of Experiments
  • Mold gate size adjusted
  • Mold gate size monitored

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Production has met the projects goal of reducing scrap rates to 3.63%.  At a production rate of 2mm parts per year a reduction in scrap rate from 9.06% to 3.63% would represent savings of $96,000.

NOTE: In March, the eight cavity version of this part started production.  This is a new item number.  The future of the two four cavity molds is not yet clear, but no production has been run on either four cavity mold since the end of January.  Because of the similarity between the four cavity and eight cavity programs, many of the lessons learned form the six sigma project done on the two four cavity molds will apply to the eight cavity mold.